Mattress construction

ABSTRACT

THIS INVENTION IS TO A CUSHION STRUCTURE FOR USE IN BEDDING AND SEATING, AND COMPRISES SPRINGS EMBEDDED WITHIN CUSHION MEMBERS FORMED OF PLASTIC FOAM MATERIAL. IT INCLUDES RETAINERS AT EITHER END OF THE COMPRESSION SPRINGS AND, IN ONE EMBODIMENT, TWO CUSHION MEMBERS BONDED IN ADJACENT RELATION AND HAVING A PLASTIC GRID EMBEDDED THEREON AT THEIR ADJACENT PORTIONS TO PROVIDE STABILITY. ANOTHER EMBODIMENT COMPRISES A SINGLE FOAM CUSHION MEMBER ON A PLATFORM TO WHICH THE COMPRESSION SPRINGS ARE OPERATIVELY CONNECTED. THE PLATFORM IS MOUNTED ON ADJUSTABLE LEGS.

Nov. 30, 1971 s. 1.. ARKIN MATTRESS CONSTRUCTION 2 Sheets-Sheet 1 Filed Nov. 17 1969 INVENTOR SANFORD L. ARKIN ATTORNEYS Nov. 30, 197] S. L. ARKIN MATTRESS CONSTRUCTION 2 Sheets-Sheet 3 Filed Nov. 17, 1969 @WAWW AV I %%%w N b, b

lllllllllllllm INVENTOR SANFORD L. ARKIN ATTORNEYS United States Patent O 3,623,171 MATTRESS CONSTRUCTION Sanford L. Arkin, 700 Alamosa Drive, Claremont, Calif. 91711 Filed Nov. 17, 1969, Ser. No. 877,099 Int. Cl. F161? 3/10; A47c 27/22, 23/04 US. Cl. 5-351 7 Claims ABSTRACT OF THE DISCLOSURE This invention is to a cushion structure for use in bedding and seating, and comprises compression springs embedded within cushion members formed of plastic foam material.

It includes retainers at either end of the compression springs and, in one embodiment, two cushion members bonded in adjacent relation and having a plastic grid embedded therein at their adjacent portions to provide stability.

Another embodiment comprises a single foam cushion member on a platform to which the compression springs are operatively connected. The platform is mounted on adjustable legs.

The present invention relates generally to cushion structures for bedding and seating, and more particularly, to such structures which include both resilient foam material and helical compression springs.

For a considerable number of years, the bedding and seating industry has undergone very few technical changes, relying, for the most part, on structures which are extremely old and mediocre. That is, many cushions, mattresses and box springs for beds are still made with ordinary compression springs which are tied together with string and over which is provided a decorative covering. Such cushion structures, it has been discovered, become very uncomfortable and break down after very little use, thus necessitating frequent repairs and reconstruction.

Modern day materials such as the new resilient plastic materials have been used only very little in the bedding and seating industries, the most noted uses being to cover plastic foam material with a decorative material to provide a cushion or pillow. These structures have exhibited serious shortcomings such as failure to maintain the proper size and shape, failure to provide the desired resiliency, and failure to provide the desired firmness and stability. For a considerable period of time, it has been realized that the bedding and seating industries could use to advantage modern techniques in providing cushions and the like.

It is an object of the present invention to provide a cushion structure for bedding and seating which is capable of affording greater resistance along the edges of the cushion than at the central portion.

Another object of the present invention is to provide a cushion structure as characterized above which is stable and less subject to breakdown than cushions of prior construction.

Another object of the present invention is to provide a cushion structure as characterized above having resilient foam plastic and metallic coil springs embedded therein, both of which can be selected according to the amount of resiliency desired. Within the same cushion structure different zones can have lesser or greater resiliency.

A still further object of the present invention is to provide a cushion structure as characterized above which is primarly formed of two cushion members of plastic foam material having aligned recesses formed therein for receiving the compression springs.

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An even further object of the present invention is to provide a cushion structure as characterized above having adjustable support legs.

Another object of the present invention is to provide a cushion structure as .characterized above which is simple and inexpensive to manufacture and which is rugged, comfortable and dependable in operation.

The novel features which I consider characteristic of my invention are set forth with particularity in the appended claims. The device itself, however, both as to its organization and mode of operation, together with additional obejcts and advantages thereof, will best be understood from the following description of specific embodiments when read in connection with the accompanying drawings, in which:

FIG. 1 is a perspective view of a mattress and box spring formed in accordance with the present invention.

FIG. 2 is an exploded sectional view of a portion of the structure of FIG. 1.

FIG. 3 is a sectional view through one of the compression spirngs and retainers therefor.

FIG. 4 is a perspective view of one of the cushion members.

FIG. 5 is a perspective view of the polyvinyl grid; and

FIG. 6 is an elevational view of one of the support legs for the structure of FIG. 1.

Like reference characters indicate corresponding parts throughout the several views of the drawings.

Referring to FIG. 1 of the drawings, there is shown therein a bedding structure 10 comprising a mattress 12 positioned on a bed spring or box spring 14. The subject invention is described with respect to cushion structures for use in the bedding industry. However, it is well appreciated that the subject invention has equal applicability to the cushion structures of the seating industry such as couches, davenports, chairs, pillows and the like. In this regard, the term cushion structure is used in the claims appended hereto in such broad context, namely as related to both the seating and bedding industry.

The cushion structures of the subject invention are believed to be useful in substantially any environment. For instance, such structures can be used to advantage not only in home seating but in seating for vehicles as well. Such vehicles might take the form of automobiles, trains, airplanes and the like. The claims appended hereto are intended to include no limitation with respect to such use or environment.

As shown most particularly in FIG. 2. of the drawings, the mattress 12 is formed of two cushion members 16 and .18. Each such member is formed of plastic foam material which is resilient and pliable, most typically referred to in the market place as either open-cell or closed-cell polyurethane. Such members 16 and 18 can be molded to the desired size and shape in any one of various diiferent types of molding machines which are well known in the art. The resiliency or density of the foam can be varied to obtain the desired comfort required.

The upper cushion member 16 is formed with a plurality of recesses 16a which are substantially cylindrical in shape, having end walls 16b. Such recesses are spaced a fixed distance from each other as shown most clearly in FIG. 4 of the drawings. This view shows the underside of cushion member 16, indicating the recesses 16a.

in like manner, the cushion member 18 is provided with a plurality of recesses 18a having end walls 18b. Such recesses 18a are cylindrical and of the same diameter as the recesses 16a, and are aligned therewith when the two cushion members 16 and 18 are placed in adjacent relation as will hereinafter become more apparent.

As shown most clearly at 16c, cushion member 16 is formed with a plurality of elongated slots between the various recesses 16a. Such slots 16c are formed at right angles to each other and are of such depth as to receive a grid structure to be hereinafter described.

In like fashion, the cushion member 18 is formed with slots 18c between the various recesses 18 a.

A cup-shaped retainer having a cylindrical side wall Zita and an end wall 20b is positioned in each of the recesses 16a and 18a against the end wall thereof. Such retainers are formed of Wear resistant materials such as metal and plastic.

As shown most particularly in FIG. 3 of the drawings, each retainer 20 is adapted to receive the end portion of a helical compression spring 2-2. Each retainer is provided with a plurality of locking nibs 200 which are formed in the cylindrical side wall 20a by a suitable forming die or punch during the forming operation of the retainer. Such nibs engage the end convolution of the particular compression spring, as shown most particularly in FIG. 3 of the drawings, to provide a unitary structure therewith.

Positioned within the slots 16c and 180 of the cushion members 16 and '18 when the latter are brought together, in a lattice work or grid 24 shown in FIG. 5. Such grid comprises a plurality of relatively thick plastic sheet members 26 which are arranged at right angles to each other and are provided with interlocking slots. Such slots extend approximately one half the width of the individual strips of plastic to provide a substantially coplanar grid when they are interlocked. Such plastic strips are preferably formed of polyvinyl plastic and are approximately onesixteenth to one-eighth inch thick.

The compression springs 22 and retainers 20 therefor are placed in the recesses 16a and 18a, and the polyvinyl grid 24 is placed in the slots 16c and 180. The cushion members 16 and 18 are then connected to each other with suitable bonding material. Thus, the cushion members are firmly secured together to form a unitary structure having the grid 24 along the horizontal mid-section thereof and coil springs imbedded therein. The springs, as will hereinafter become more apparent, can be selected as to their size and compressive force, to provide the desired cushioning effect throughout the entire mattress 10. That is, if it is desired to provide a firm or stiff outer edge portion for mattress 10, compression springs of higher compressive force can be provided at such locations. The intermediate or central portion of the mattress can be provided with softer springs if desired. It is thus seen that the firmness of the entire mattress 10 can be selected as desired merely by selecting the appropriate type of springs and by varying the resilience or density of the foam.

Secured to the peripheral surface of cushion members '16 and 18, as by gluing and the like, are fastening tapes 28 to which the outer covering 30 can be fastened as by sewing and the like. This causes the covering to be firmly secured to the polyfoam members, while nonetheless being movable relative thereto.

The box spring 14 is constructed in a manner similar to that described above with respect to the mattress 10. As shown in FIG. 2 of the drawings, the box spring comprises a polyfoam member 40 having a plurality of recesses 40a formed therein. Each such recess is provided with a retainer 20 as shown in FIG. 2. Another retainer 20 is secured to a platform 42 in any appropriate manner as by tacking, gluing or the like. Although it has been found that such retainers 20 are held against the platform 42 by the force of the compression springs, it is desirable to additionally secure them. thereto.

Within each of the recesses 40a of the cushion member 40 there is provided a compression spring 22 mounted within the respective retainers 20. The cushion member 40 is then secured to platform 42 by any well-known means such as bonding or the like. This then provides a unitary structure having a firm platform 42 with a polyfoam member and compression springs thereon. A covering 44 is provided for the polyfoam cushion member 40 by means of tacking strips or fastening tapes 46 glued to the cushion member.

As shown most clearly in FIGS. 2 and 6 of the drawings, there is provided for the box spring 14 support means 50. Such support means may take substantially any desired form, but should be provided with adjustable mounting means 52. As shown in the drawings, mounting means 52 comprises an elongated channel member 54 having elongated J-shaped edges 54a and 54b which receive'a generally M-shaped bracket 56. Such bracket is formed with a pair of substantially vertical opposite ends which engage the ]-shaped edges 54a and 54b of channel member 54 as shown most clearly in FIG. 6 of the drawing. Bracket 56 is formed with a threaded through opening 56a which receives a stud 58 in a support leg 60. Such stud is threaded into the bracket 56 to be retained thereby in fixed position relative to channel member 54. The leg 60; of course, can take substantially any desired shape and can be made of substantially any desired materials.

As will be readily apparent to those persons skilled in the art, the leg 61 can be repositioned along the length of channel member 54, merely by turning the leg 60 such as to loosen the engagement between stud 58 and bracket 56, and thereafter moving the leg along the channel 54 to any desired position. The leg 60 is then turned so as to tighten the bracket 56 against channel member 54.

As shown in FIG. 1 of the drawings, brackets 62 may be mounted at one end of box spring 14 to receive a headboard for the bed structure. This may be a desirable feature for commercial establishments such as hotels and motels.

It is thus seen that the present invention provides a cushion structure for the bedding and seating industries which is capable of providing many advantages over the prior art.

What is claimed is:

1. Bedding and seating cushion structure comprising in combination, a first flexible cushion member formed of plastic foam material with a plurality of recesses, a second flexible cushion member formed of foam plastic material with a plurality of recesses aligned with the recesses of said first member to provide a plurality of cavities, a compression spring in each of said cavities, a cup-shaped retainer within each of said recesses for the respective end portions of the compression spring therein, each of said cushion members being formed with slots at adjacent portions thereof, a grid of stiffening members positioned in said slots, and bonding material interposing between said first and second members to retain the same in adjacent relation.

2. Bedding and seating cushion structure according to claim 1 wherein said slots and stiffening members are disposed at right angles to each other to provide stability for said cushion structure in different directions.

3. Bedding and seating cushion structure according to claim 2 wherein said stiffening members are formed of polyvinyl plastic material approximately one-sixteenth to one-eighth inch thick.

4. Bedding and seating cushion structure according to claim 3 wherein said stiffening members at right angles to each other are formed with interconnecting slots to form the grid.

5. Bedding and seating cushion structure comprising in combination, a flexible cushion member formed of plastic foam material with a plurality of separated individual recesses, a cup-shaped retainer in each of said recesses, a platform for supporting said cushion member, a cupshaped retainer for each of said recesses secured to said platform for individual alignment with said recesses, and a compression spring in each of said recesses having its opposite ends in the said retainers associated with said recess and surrounded by said foam material, retainers and platform but separated from every other spring in said structure.

6. Bedding and seating cushion structure according to 5 6 claim 5 including support legs for said structure, and ad- 3,160,895 12/ 1964 Stafford 5310 X justable mounting means for said support legs. 3,251,078 5/ 1966 Calla 5-353 7. Bedding and seating cushion structure according to 3,439,466 4/ 1969 Schreyer 312--194 X claim 6 wherem said mountmg means comprises an elon- FOREIGN PATENTS gated channel member secured to said platform and a 5 mounting bracket in said channel member for each sup- 3131753 6/1929 Great Britain- P r eg References Cited CASMIR A. NUNBERG, Primary Examiner UNITED STATES PATENTS us. 01. X.R.

,8 3, 2/1958 Barry 5310 10 5 309, 31o, 355;267-84, 143

3,031,690 5/1962 Ramsay 5-353 

